Production of crystalline carbon structure networks

ABSTRACT

The invention pertains to a process for the production of crystalline carbon structure networks in a reactor  3  which contains a reaction zone  3   b  and a termination zone  3   c , by injecting a thermodynamically stable micro-emulsion c, comprising metal catalyst nanoparticles, into the reaction zone  3   b  which is at a temperature of above 600° C., preferably above 700° C., more preferably above 900° C., even more preferably above 1000° C., more preferably above 1100° C., preferably up to 3000° C., more preferably up to 2500° C., most preferably up to 2000° C., to produce crystalline carbon structure networks e, transferring these networks e to the termination zone  3   c , and quenching or stopping the formation of crystalline carbon structure networks in the termination zone by spraying in water d.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.16/310,750 filed Dec. 17, 2018, which application is the National Phaseof International Patent Application No. PCT/EP2017/065994, filed Jun.28, 2017, published on Apr. 1, 2018 as WO 2018/002137 A1, which claimspriority to European Application No. 16176599.5, filed Jun. 28, 2016 andEuropean Application No. 17150513.4, filed Jan. 6, 2017. The contents ofthese applications are herein incorporated by reference in theirentirety.

FIELD OF THE INVENTION

The invention is in the field of manufacturing crystalline carbonstructure networks with improved properties, and directed to new methodsfor manufacturing such structure networks. The invention is particularlyin the field of carbon black manufacturing.

BACKGROUND TO THE INVENTION

Carbon black industry focuses on providing an allotrope of carbon mainlydiffering from graphite and amorphous carbon by its physicalarrangement, for use in manufacturing rubber articles, such as tires,etc., in polygraphy, electronics and cable coatings, in the productionof varnishes and paints, including use applications in which reinforcingand/or pigmentary properties of carbon black are required.

Various different processes or techniques are known in the art forproducing carbon black. Carbon black is mainly produced by partialcombustion processes, starting from a carbon containing gas such asmethane or acetylene. This process is sometimes referred to as a furnacecarbon black producing process, and it employs a furnace having a burneror combustion chamber followed by a reactor. The furnace process istypically characterized by low oxygen levels, low densities, shortresidence times and high temperatures. As a first step of the furnacecarbon black production process, hydrocarbons are atomized at typicaltemperatures from 1200 to 1900° C., as is described in UllmannsEncyklopadie der technischen Chemie, Volume 14, page 637-640 (1977). Tothat end, a zone having a high energy density is produced by burning afuel gas or a liquid fuel with oxygen or air, and the carbon black rawmaterial is injected thereto. The carbon black feedstock is atomized inthese hot combustion conditions; oxygen levels are on average suppliedat a rate of two volumes of carbon black feedstock to about one volumeof oxygen, in order to achieve the oxygen being completely consumed inthe combustion process. The structure and/or the porosity of the carbonblack end product may be influenced by the presence of alkali metal oralkaline earth metal ions during the carbon black formation, and suchadditives are therefore frequently added in the form of aqueoussolutions, which are sprayed onto the carbon black raw materialagglomerates. The reaction is terminated only by the injection of water(quenching) and the carbon black is collected at a temperature of about200-250° C., and separated from the waste gas by means of conventionalseparators or filters. Because of its low bulk density, the resultingcarbon black is then granulated, for instance carried out in apelletizing machine with the addition of water to which small amounts ofa pelletizing auxiliary may be added. In chronological order, and by nowmeans limiting the art on furnace carbon black technology, U.S. Pat.Nos. 2,672,402, 4,292,291, 4,636,375, WO2000/032701 and US 2004/0248731provide a description of traditional or conventional carbon blackproduction. Their contents are herewith incorporated by reference. Ofnote, there are also alternative processes such as the lamp blackprocess, thermal black, acetylene black and channel black process whichall are variations on the process described above, in the end producinga type of carbon black. Most innovative is the plasma black carbonprocess, advantageously avoiding direct carbon dioxide emissions, andreducing fossil fuel consumption. In essence, these oxygen-poor carbonblack manufacture methods are very similar, except for finding differentways of yielding pyrolysis temperature conditions. Hitherto the industryis however still struggling to produce carbon black through oxygen-poorreducing processes with parameters comparable to those of carbon blackproduced through traditional partial combustion.

GB1514130 (in 1976) also discloses a method of producing carbon blackfrom liquid hydrocarbons, by partial combustion and cracking of thehydrocarbons in a furnace plant. An emulsion of water and a liquidhydrocarbon is introduced into the combustion zone of a furnace, with anaim to use the water to optimize atomisation of the hydrocarbon. Theprocess of the “thermal” atomisation of the liquid hydrocarbons, whichthemselves are only partly capable of being evaporated, is due to theexplosion-like evaporation of the water at the moment when the emulsionis passed into the hot combustion zone. The process results in highercarbon black yields and shorter reaction times. The type of emulsionthat could be used is not described. No different structures arereported.

U.S. Pat. No. 3,494,740 (dated 1970) also discusses carbon blackproduction by introducing into the reaction zone of a carbon blackfurnace an additive comprising a metal selected from the groupconsisting of nickel, vanadium, iron, cobalt, and mixtures thereof, inan amount within the range of from 1 to 80 parts by weight per millionparts by weight of the hydrocarbon feedstock to said furnace. The metalmay be provided in water, oil or emulsion, in order to realize uniformdispersion in the hydrocarbon feed. The carbon black properties arementioned in table 1. The type of emulsion that could be used is notdescribed. No different structures are reported.

US2015/064099 relates to methods for production of carbon black usingpreheated feedstock with fouling control. Water is used for quenching.

SUMMARY TO THE INVENTION

The inventors found that well-established reducing (pyrolysis) oroxidizing (combustion) carbon black manufacturing processes can be usedto produce networks of crystalline carbon structures having all kinds ofadvantageously improved electrical, mechanical and thermal properties,by introducing the concept of single-phase emulsification usingthermodynamically stable micro-emulsions of the w/o or bicontinuoustype, with metal catalyst nanoparticles, to conventional (furnace)carbon black production. The invention thus relates to a process forproducing crystalline carbon structure networks by providing athermodynamically stable single-phase emulsion comprising an oil,preferably C14 of higher, more preferably a carbon black feedstock oil,water and at least one surfactant, and also metal catalystnanoparticles, and subjecting the emulsion, preferably the emulsifiedcarbon black feedstock, to a carbon black manufacturing process,carbonizing said carbon black feedstock at increased temperatures above600° C., preferably above 700° C., more preferably above 900° C., evenmore preferably above 1000° C., most preferably above 1100° C.,preferably up to 3000° C., more preferably up to 2500° C., particularlyup to 2000° C.

Throughout the text and claims, a ‘single-phase emulsion’ is awater-in-oil (w/o) micro-emulsion or a bicontinuous micro-emulsioncomprising metal catalyst nanoparticles.

In a related aspect, the invention pertains to the use of such asingle-phase emulsion, preferably an emulsified carbon black feedstock(i.e. a single-phase emulsion comprising carbon black feedstock) forcarbonizing the emulsion in a carbon black manufacture process,preferably a furnace carbon black manufacture process, thus obtainingcrystalline carbon structure networks. The emulsion is preferablysprayed and atomized into the reactor at the above elevatedtemperatures. Again, it was found that the single-phase emulsion shouldbe a w/o or bicontinuous micro-emulsion comprising metal catalystnanoparticles.

Through the eyes of the skilled person, the use of water should at leastbe minimized and preferably banned from the reaction sector in atraditional carbon black manufacturing process to obtain proper yieldsand preferred spherical carbon black structures, where water is only tobe used for terminating the carbon black reaction further downstream inthe reactor. At best water is sometimes used as a carrier in sprayingalkali metal and alkaline earth metal ions onto the carbon blackmaterial, where in the final stages of the agglomeration process theporosity of the carbon black product could be fine-tuned to the marketneeds. Depending on the source, carbon black feedstock may in fact evenbe dewatered prior to introduction to the process, in order toincreasing the fuel density and optimizing atomization. With thatwide-spread reluctance of using any—let alone much—water duringtraditional carbon black manufacture, other than for quenching purposesin the closing stages, the idea of emulsifying the carbon blackfeedstock prior to atomization goes beyond the skilled person'simaginations. However, the inventors found that amending theconventional carbon black manufacture by atomizing a stable one-phaseemulsion comprising a carbon black feedstock oil into the reactor has adramatic impact in that a novel crystalline carbon material is obtainedcomprising of a network of structures, typically nanofibers, instead ofthe normally obtained amorphous carbon black based on aggregates fromspherical particles. The crystalline carbon network structures are sodifferent in morphology that they constitute properties that aredifferent and even superior to carbon black aggregates, some of whichhave been exploited further below.

Without wishing to be bound by any theory, the inventors believe thatthe orientation and structuring of the surfactant molecules, oil phaseand water phase together with the metal catalyst nanoparticles give riseto the network-forming process that is unique to the new material and tothe process. It was found that metal catalyst nanoparticles areessential. The micro- and macro-structures of the emulsions (eitherwater-in-oil or bicontinuous) are thought to act as aprecursor/blue-print for the final carbon structure network, of whichthe carbon-containing fractions (oil phase and surfactant) will form thefibers and junctions, whilst the water fraction helps orienting theoil/surfactant phase and network porosity. The presence of a metalcatalyst promotes the carbonization of the carbon components into afiber structure instead of the normally obtained spherical orientation.A blend of an immiscible oil and water phase will not yield thesestructures, i.e. without a metal catalyst in a thermodynamically stablematrix present. Once the emulsion is atomized at high temperatures thecarbonization process instantly “freezes” the carbon fractions in itsemulsion-structure in the presence of a metal catalyst, while the waterevaporates, leaving a network of (nano)fibers. In that process, theinventors found it is key to provide the carbon raw material, i.e. theoil, such as carbon black feedstock, in the form of a single-phaseemulsion as described above, to the atomization process. The inventorsalso found that a mere mixture of water and feedstock or otherwisethermodynamically instable emulsions are detriment to the process, andwill not yield the crystalline carbon structure networks. Furtherevidence is provided below.

The inventors also found that the single-phase emulsions subjected toatomization and subsequent carbonization should comprise metalnanoparticles which act as catalyzers in forming these crystallinenetworks. An increasing concentration of metal catalyst nanoparticlesfurther enhances yields. It is essential to use bicontinuous orwater-in-oil (w/o) micro-emulsions, wherein the emulsions comprise metalcatalyst nanoparticles, which emulsions comprise of a continuousoil/surfactant phase thus already forming a network structure.Bicontinuous micro-emulsions are most preferred.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a schematic diagram of a continuous furnace carbon blackproducing process in accordance with the present invention whichcontains, along the axis of the reactor 3, a combustion zone 3 a, areaction zone 3 b and a termination zone 3 c, by producing a stream ofhot waste gas a1 in the combustion zone by burning a fuel a in anoxygen-containing gas b and passing the waste gas a1 from the combustionzone 3 a into the reaction zone 3 b, spraying (atomizing) a single-phaseemulsion c in the reaction zone 3 b containing the hot waste gas,carbonizing said emulsion at increased temperature, and quenching orstopping the reaction in the termination zone 3 c by spraying in waterd, to obtain crystalline carbon structure networks e according to theinvention;

FIG. 1B is a schematic diagram of a semi-batch carbon black producingprocess where a single-phase emulsion c is atomized through a nozzle 4at the top of the reactor 3 into the reactor zone 3 b at elevatedtemperatures, carbonizing said emulsion at the elevated temperature inthe reactor zone 3 b, and collecting the crystalline carbon structurenetworks e at the bottom of the reactor. Additionally two gas-inlets arepresent that enter the reactor from the top, for adding inert gas f,preferably nitrogen for controlling and/or depletion of oxygen-levels,and for introducing a carbon-containing gas g into the reactor,preferably acetylene or ethylene.

FIGS. 2A and 2B are SEM pictures of carbon black and carbon structurenetworks, respectively;

FIG. 3 shows a SEM picture of crystalline carbon structure networksobtained in a bicontinuous microemulsion with 100 mM FeCl3 metalcatalyst;

FIG. 4 depicts the elasticity modulus according to ISO 527 for carbonnetworks (squares) and glass fibers (circles), showing mechanicalstrength for the crystalline networks that is comparable to that of thefibers. Carbon black was found not to bring any reinforcing propertiesto the composite; and

FIG. 5 shows volume resistivity for different compounds (polyamide PA6;squares; PET: circles) prepared with different loadings of crystallinecarbon structure networks prepared using the recipe according to example1.

EMBODIMENTS OF THE INVENTION

-   1. A process for the production of crystalline carbon structure    networks in a reactor 3 which contains a reaction zone 3 b and a    termination zone 3 c, by injecting a water-in-oil or bicontinuous    micro-emulsion c comprising metal catalyst nanoparticles, into the    reaction zone 3 b which is at a temperature of above 600° C.,    preferably above 700° C., more preferably above 900° C., even more    preferably above 1000° C., more preferably above 1100° C.,    preferably up to 3000° C., more preferably up to 2500° C., most    preferably up to 2000° C., to produce crystalline carbon structure    networks e, transferring these networks e to the termination zone 3    c, and quenching or stopping the formation of crystalline carbon    structure networks in the termination zone by spraying in water d.-   2. The process according to embodiment 1, said reactor being a    furnace carbon black reactor 3 which contains, along the axis of the    reactor 3, a combustion zone 3 a, a reaction zone 3 b and a    termination zone 3 c, by producing a stream of hot waste gas a1 in    the combustion zone by burning a fuel a in an oxygen-containing gas    b and passing the waste gas a1 from the combustion zone 3 a into the    reaction zone 3 b, spraying a water-in-oil or bicontinuous    micro-emulsion c comprising metal catalyst nanoparticles, in the    reaction zone 3 b containing the hot waste gas, carbonizing said    emulsion at a temperature of above 600° C., preferably above 700°    C., more preferably above 900° C., even more preferably above 1000°    C., more preferably above 1100° C., preferably up to 3000° C., more    preferably up to 2500° C., most preferably up to 2000° C., and    quenching or stopping the reaction in the termination zone 3 c by    spraying in water d, to yield crystalline carbon structure networks    e.-   3. The process according to any one of the preceding embodiments,    wherein the oil phase in the emulsion is aromatic and/or aliphatic,    preferably comprising at least 50 wt % C14 or higher, based on the    total weight of the oil phase.-   4. The process according to any one of the preceding embodiments,    said emulsion comprising at least 1 mM metal catalyst nanoparticles,    preferably having an average particle size between 1 and 100 nm.-   5. A crystalline carbon structure network obtainable by the process    according to any one of the preceding embodiments, wherein said    carbon structures are chemically interconnected through a multitude    of junctions, including Y- and H-junctions.-   6. The network according to embodiment 5, having at least one,    preferably at least two, more preferably at least three, most    preferably all of the following properties:    -   (i) Iodine Adsorption Number (IAN) of at least 250 mg/g        according to ASTM D1510;    -   (ii) Nitrogen Surface Area (N2SA) of at least 250 m2/g according        to ASTM D6556;    -   (iii) Statistical Thickness Surface Area (STSA) of at least 120        m2/g according to ASTM D6556;    -   (iv) Oil Absorption Number (OAN) of at least 150 cc/100 g        according to ASTM D2414.-   7. The network according to embodiment 5 or 6, wherein said    structures have an average thickness of 1-400 nm, preferably between    5 and 350 nm, more preferably up to 100 nm, in one embodiment    between 50 and 100 nm, and/or an average length in the range of    100-10000 nm, preferably 200-5000 nm, more preferably 500-5000 nm;    and/or wherein the structures have an average aspect ratio of length    to thickness of at least 2.-   8. A composite comprising carbon structure networks according to any    one of embodiments 5-7, further comprising one or more polymers, for    instance for adding mechanical strength, electrical conductivity or    thermal conductivity to said polymer-based composite, and wherein    said networks are in any amount of 1-70 wt %, preferably 10-50 wt %,    more preferably between 20-40 wt %, based on the total polymer    weight in the composite.-   9. The composite according to embodiment 8, showing an E modulus    increasing with network concentration as measured according to ISO    527.-   10. Use of an emulsified carbon black feedstock in a carbon black    manufacture process, preferably a furnace carbon black manufacture    process, for producing crystalline carbon structure networks.-   11. A process for the semi-batch production of the crystalline    carbon structure networks in a reactor 3 where a water-in-oil or    bicontinuous micro-emulsion c comprising metal catalyst    nanoparticles is injected from the top of the reactor 3, preferably    through spraying using an aerosol inlet 4, to obtain an aerosol, and    wherein said networks e are formed at an increased temperature of at    least 600° C., preferably 700-1200° C. and deposited at the bottom    of the reactor, and wherein the increased temperature is obtained    using pyrolysis (e.g. heat source outside reactor, using N2,    depleted of oxygen) or by combustion (heat source inside reactor,    using air or oxygen).-   12. A process for the continuous production of the crystalline    carbon structure networks in a reactor 3 where a water-in-oil or    bicontinuous micro-emulsion c comprising metal catalyst    nanoparticles is injected from the top of the reactor 3, said    reactor preferably being a thermal black reactor, preferably through    spraying using an aerosol inlet 4, to obtain an aerosol, and wherein    said networks e are formed at an increased temperature of at least    600° C., preferably 700-1200° C. and deposited at the bottom of the    reactor, and wherein the increased temperature is obtained using    combustion (heat source inside reactor, using air or oxygen), but    wherein the emulsion is injected only under pyrolysis conditions.

DETAILED DESCRIPTION

The invention can be described best as a modified carbon blackmanufacturing process, wherein ‘modified’ is understood that a suitableoil, preferably an oil comprising at least 14 C atoms (>C14) such ascarbon black feedstock oil (CBFS), is provided to the reaction zone of acarbon black reactor as part of a single-phase emulsion, being athermodynamically stable micro-emulsion, comprising metal catalystnanoparticles. The emulsion is preferably provided to the reaction zoneby spraying, thus atomizing the emulsion to droplets. While the processcan be carried out batch or semi-batch wise, the modified carbon blackmanufacturing process is advantageously carried out as a continuousprocess. The single-phase emulsion is a micro-emulsion comprising metalcatalyst nanoparticles. The preferred single-phase emulsion comprisesCBFS oil, and may be referred to as ‘emulsified CBFS’ in the context ofthe invention.

In one embodiment, the invention pertains to a process for theproduction of the crystalline carbon structure networks according to theinvention in a reactor 3 which contains a reaction zone 3 b and atermination zone 3 c, by injecting a single-phase emulsion c, being amicro-emulsion comprising metal catalyst nanoparticles, preferably aCBFS-comprising emulsion, according to the invention into the reactionzone 3 b which is at a temperature of above 600° C., preferably above700° C., more preferably above 900° C., even more preferably above 1000°C., more preferably above 1100° C., preferably up to 3000° C., morepreferably up to 2500° C., most preferably up to 2000° C., to producecrystalline carbon structure networks e, transferring these networks eto the termination zone 3 c, and quenching or stopping the formation ofcrystalline carbon structure networks in the termination zone byspraying in water d. The single-phase emulsion is preferably sprayedinto the reaction zone. Reference is made to FIG. 1A.

In a preferred embodiment, the invention pertains to a process for theproduction of the crystalline carbon structure networks according to theinvention in a furnace carbon black reactor 3 which contains, along theaxis of the reactor 3, a combustion zone 3 a, a reaction zone 3 b and atermination zone 3 c, by producing a stream of hot waste gas a1 in thecombustion zone by burning a fuel a in an oxygen-containing gas b andpassing the waste gas a1 from the combustion zone 3 a into the reactionzone 3 b, spraying (atomizing) a single-phase emulsion c according tothe invention, preferably a micro-emulsion comprising metal catalystnanoparticles, preferably a CBFS-comprising emulsion, in the reactionzone 3 b containing the hot waste gas, carbonizing said emulsion atincreased temperatures (at a temperature of above 600° C., preferablyabove 700° C., more preferably above 900° C., even more preferably above1000° C., more preferably above 1100° C., preferably up to 3000° C.,more preferably up to 2500° C., most preferably up to 2000° C.), andquenching or stopping the reaction (i.e. the formation of crystallinecarbon structure networks e) in the termination zone 3 c by spraying inwater d. The reaction zone 3 b comprises at least one inlet (preferablya nozzle) for introducing the emulsion, preferably by atomization.Reference is made to FIG. 1A.

Residence times for the emulsion in the reaction zone of the furnacecarbon black reactor can be relatively short, preferably ranging from1-1000 ms, more preferably 10-100 ms.

In accordance with conventional carbon black manufacturing processes,the oil phase can be aromatic and/or aliphatic, preferably comprising atleast 50 wt % C14 or higher, more preferably at least 70 wt % C14 orhigher (based on the total weight of the oil). List of typical oilswhich can be used, but not limited to obtain stable emulsions are carbonblack feedstock oils (CBFS), phenolic oil, anthracene oils,(short-medium-long chain) fatty acids, fatty acids esters and paraffins.The oil is preferably a C14 or higher. In one embodiment, the oilpreferably has high aromaticity. Within the field, the aromaticity ispreferably characterized in terms of the Bureau of Mines CorrelationIndex (BMCI). The oil preferably has a BMCI>50. In one embodiment, theoil is low in aromaticity, preferably having a BMCI<15.

CBFS is an economically attractive oil source in the context of theinvention, and is preferably a heavy hydrocarbon mix comprisingpredominantly C14 to C50, the sum of C14-C50 preferably amounting to atleast 50 wt %, more preferably at least 70 wt % of the feedstock. Someof the most important feedstocks used for producing carbon black includeclarified slurry oil (CSO) obtained from fluid catalytic cracking of gasoils, ethylene cracker residue from naphtha steam cracking and coal taroils. The presence of paraffins (<C15) substantially reduces theirsuitability, and a higher aromaticity is preferred. The concentration ofaromatics determines the rate at which carbon nuclei are formed. Thecarbon black feedstock preferably has a high BMCI to be able to offer ahigh yield with minimum heat input hence reducing the cost ofmanufacturing. In a preferred embodiment, and in accordance with currentCBFS specifications, the oil, including mixtures of oil, has a BMCIvalue of more than 120. While the skilled person has no difficultiesunderstanding which are suitable CBFS, merely as a guide it is notedthat—from a yield perspective—a BMCI value for CBFS is preferably morethan 120, even more preferably more than 132. The amount of asphaltenein the oil is preferably lower than 10 wt %, preferably lower than 5.0wt % of the CBFS weight. The CBFS preferably has low sulfur content, assulfur adversely affects the product quality, leads to lower yield andcorrodes the equipment.

It is preferred that the sulfur content of the oil according to ASTMD1619 is less than 8.0 wt %, preferably below 4.0 wt % more preferablyless than 2.0 wt %.

The emulsion, preferably a CBFS-comprising emulsion, is a “single-phaseemulsion” which is understood to mean that the oil phase and the waterphase optically appear as one miscible mixture showing no physicalseparation of oil, water or surfactant to the naked eye. Thesingle-phase emulsion can be a macro-emulsion or a micro-emulsion, andcan be either kinetically or thermodynamically stable. The process bywhich an emulsion completely breaks (coalescence), i.e. the systemseparates into bulk oil and water phases, is generally considered to becontrolled by four different droplet loss mechanisms, i.e., Brownianflocculation, creaming, sedimentation flocculation anddisproportionation.

A ‘stable single-phase emulsion’ within the context of the invention isunderstood to mean that the emulsion shows no physical separationvisible to the eye, preferably reflected in terms of the emulsion notshowing any change in pH by more than 1.0 pH unit and/or the emulsionnot showing any change in viscosity by more than 20%, over a period oftime that exceeds the carbon structure network production time. The term‘stable’ can mean ‘thermodynamically stable’ or ‘kinetically stable’ (byadding energy, i.e. through mixing). In practice, the single-phaseemulsion is regarded stable if no de-mixing optically arises, i.e. asingle-phase is retained, for a period of at least 1 minute afterpreparation of the emulsion. It is thus preferred that the emulsionmaintains its pH within 1.0 pH unit and/or its viscosity with less than20% variation over a period of time of at least 1 minute, preferably atleast 5 minutes after preparation. While for handling purposes anextended stability is preferred, it is noted that the manufacturingprocess can still benefit from using emulsions stable over relativelyshort time spans of 1 minute, preferably 5 minutes: By adding energy(mixing) the stability of the emulsion can be extended, and short-termstability can be extended using in-line mixing. While macro-emulsionsare not thermodynamically stable, and will always revert to theiroriginal, immiscible separate oil and water phases, the break down ratecan be sufficiently slow to render it kinetically stable for the lengthof the manufacturing process.

Provided that a stable, single-phase emulsion is obtained, the amountsof water and oil are not regarded limiting, but it is noted that reducedamounts of water (and increased amounts of oil) improve yields. Thewater content is typically between 5 and 50 wt % of the emulsion,preferably 10-40 wt %, even more preferably up to 30 wt %, morepreferably 10-20 wt % of the emulsion. While higher amounts of water canbe considered, it will be at the cost of yield. Without wishing to bebound by any theory, the inventors believe that the water phaseattributes to the shape and morphology of the networks thus obtained.

The choice of surfactant(s) is not regarded a limiting factor, providedthat the combination of the oil, water and surfactant(s) results in astable micro-emulsion as defined here above. As further guidance to theskilled person, it is noted that the surfactant can be selected on thebasis of the hydrophobicity or hydrophilicity of the system, i.e. thehydrophilic-lipophilic balance (HLB). The HLB of a surfactant is ameasure of the degree to which it is hydrophilic or lipophilic,determined by calculating values for the different regions of themolecule, according to the Griffin or Davies method. The appropriate HLBvalue depends on the type of oil and the amount of oil and water in theemulsion, and can be readily determined by the skilled person on thebasis of the requirements of retaining a thermodynamically stable,single phase emulsion as defined above. It is found that an emulsioncomprising more than 50 wt % oil, preferably having less than 30 wt %water phase, would be stabilized best with a surfactant having an HLBvalue above 7, preferably above 8, more preferably above 9, mostpreferably above 10. On the other hand, an emulsion with at most 50 wt %oil would be stabilized best with a surfactant having an HLB value below12, preferably below 11, more preferably below 10, most preferably below9, particularly below 8. The surfactant is preferably selected to becompatible with the oil phase. In case the oil is a CBFS-comprisingemulsion with a CBFS, a surfactant with high aromaticity is preferred,while an oil with low BMCI, such as characterized by BMCI<15, would bestabilized best using aliphatic surfactants. The surfactant(s) can becationic, anionic or non-ionic, or a mixture thereof. One or morenon-ionic surfactants are preferred, in order to increase the yieldssince no residual ions will be left in the final product. In order toobtain a clean tail gas stream, the surfactant structure is preferablylow in sulfur and nitrogen, preferably free from sulfur and nitrogen.Non-limiting examples of typical non-ionic surfactants which can be usedto obtain stables emulsions are commercially available series of tween,span, Hypermer, Pluronic, Emulan, Neodol, Triton X and Tergitol.

In the context of the invention, a micro-emulsion is a dispersion madeof water, oil (preferably CBFS), and surfactant(s) that is a singleoptically isotropic and thermodynamically stable liquid with disperseddomain diameter varying approximately from 1 to 500 nm, preferably 1 to100 nm, usually 10 to 50 nm. In a micro-emulsion the domains of thedispersed phase are either globular (i.e. droplets) or interconnected(to give a bicontinuous micro-emulsion). In a preferred embodiment, thesurfactant tails form a continuous network in the oil-phase of awater-in-oil (w/o) emulsion or bicontinuous emulsion. The water domainsshould contain a metal catalyst, preferably having an average particlesize between 1 nm and 100 nm.

The single-phase emulsion, i.e. a w/o or bicontinuous micro-emulsion,preferably a bicontinuous micro-emulsion, further comprises metalcatalyst nanoparticles preferably having an average particle sizebetween 1 and 100 nm. The skilled person will find ample guidance in thefield of carbon nanotubes (CNTs) to produce and use these kinds ofnanoparticles. These metal nanoparticles are found to improve networkformation in terms of both rates and yields, and reproducibility.Methods for manufacturing suitable metal nanoparticles are found inVinciguerra et al. “Growth mechanisms in chemical vapour depositedcarbon nanotubes” Nanotechnology (2003) 14, 655; Perez-Cabero et al.“Growing mechanism of CNTs: a kinetic approach” J. Catal. (2004) 224,197-205; Gavillet et al. “Microscopic mechanisms for the catalystassisted growth of single-wall carbon nanotubes” Carbon. (2002) 40,1649-1663 and Amelinckx et al. “A formation mechanism for catalyticallygrown helix-shaped graphite nanotubes” Science (1994) 265, 635-639,their contents about manufacturing metal nanoparticles hereinincorporated by reference.

The metal catalyst nanoparticles are used in a bicontinuous or w/omicroemulsion, preferably a CBFS-comprising bicontinuous or w/omicro-emulsion. In one embodiment, a bicontinous micro-emulsion is mostpreferred. Advantageously, the uniformity of the metal particles iscontrolled in said (bicontinuous) micro-emulsion by mixing a first(bicontinuous) micro-emulsion in which the aqueous phase contains ametal complex salt capable of being reduced to the ultimate metalparticles, and a second (bicontinuous) micro-emulsion in which theaqueous phase contains a reductor capable of reducing said metal complexsalt; upon mixing the metal complex is reduced, thus forming metalparticles. The controlled (bicontinuous) emulsion environment stabilizesthe particles against sintering or Ostwald ripening. Size,concentrations and durability of the catalyst particles are readilycontrolled. It is considered routine experimentation to tune the averagemetal particle size within the above range, for instance by amending themolar ratio of metal precursor vs. the reducing agent. An increase inthe relative amount of reducing agent yields smaller particles. Themetal particles thus obtained are monodisperse, deviations from theaverage particle size are preferably within 10%, more preferably within5%. Also, the present technology provides no restraint on the actualmetal precursor, provided it can be reduced. Non-limiting examples ofeffective catalyst species are the noble metals (Pt, Pd, Au, Ag),iron-family elements (Fe, Co and Ni), Ru, and Cu. Suitable metalcomplexes are but are not limited to (i) platinum precursors such asH2PtCl6; H2PtCl6·xH2O; K2PtCl4; K2PtCl4·xH2O; Pt(NH3)4(NO3)2;Pt(C5H7O2)2, (ii) ruthenium precursors such as Ru(NO)(NO3)3; Ru(dip)3Cl2[dip=4,7-diphenyl-1,10-fenanthroline]; RuCl3, or (iii) palladiumprecursors such as Pd(NO3)2, or (iv) nickel precursors such as NiCl2 orNiCl2·xH2O; Ni(NO3)2; Ni(NO3)2·xH2O; Ni(CH3COO)2; Ni(CH3COO)2·xH2O;Ni(AOT)2 [AOT=bis(2-ethylhexyl)sulphosuccinate]. Non-limiting suitablereducing agents are hydrogen gas, sodium boron hydride, sodiumbisulphate, hydrazine or hydrazine hydrate, ethylene glycol, methanoland ethanol. Also suited are citric acid and dodecylamine. The type ofmetal precursor is not an essential part of the invention. The metal ofthe particles of the (bicontinuous) micro-emulsion are preferablyselected from the group consisting of Pt, Pd, Au, Ag, Fe, Co, Ni, Ru andCu, and mixtures thereof, in order to control morphology of the carbonstructures networks ultimately formed. The metal nanoparticles end upembedded inside these structures where the metal particles arephysically attached to the structures. While there is no minimumconcentration of metal particles at which these networks are formed—infact networks are formed using the modified carbon black manufacturingprocess according to the invention—it was found that the yields increasewith the metal particle concentrations. In a preferred embodiment, theactive metal concentration is at least 1 mM, preferably at least 5 mM,preferably at least 10 mM, more preferably at least 15 mM, morepreferably at least 20 mM, particularly at least 25 mM, most preferablyup to 3500 mM, preferably up to 3000 mM. In one embodiment, the metalnanoparticles comprise up to 250 mM. These are concentrations of thecatalyst relative to the amount of the aqueous phase of the(bicontinuous) micro-emulsion.

Atomization of the single-phase emulsion, preferably a CBFS-comprisingemulsion, is preferably realized by spraying, using a nozzle-system 4,which allows the emulsion droplets to come in contact with the hot wastegas a1 in the reaction zone 3 b, resulting in traditional carbonization,network formation and subsequent agglomeration, to produce crystallinecarbon structure networks e according to the invention. The injectionstep preferably involves increased temperatures above 600° C.,preferably between 700 and 3000° C., more preferably between 900 and2500° C., more preferably between 1100 and 2000° C.

In a different but related aspect of the invention, the inventionpertains to a process for the semi-batch production of the crystallinecarbon structure networks according to the invention in a reactor 3where a single-phase emulsion c according to the invention is injectedfrom the top of the reactor 3, preferably through spraying using anaerosol inlet 4, to obtain an aerosol, and wherein said networks e areformed at a temperature of at least 600° C., preferably 700-1200° C. anddeposited at the bottom of the reactor furnace. The elevated temperatureand reaction conditions may be achieved using pyrolysis (e.g. heatsource outside reactor, using N2, depleted of oxygen) or by combustion(heat source inside reactor, using air or oxygen). In a furtherembodiment, the semi-batch process is conveniently operated with acarbon feed gas above its cracking temperature such as methane, ethane,propane, butane, ethylene, acetylene and propylene, carbon monoxide,oxygenated hydrocarbons such as methanol; aromatic hydrocarbons such astoluene, benzene and naphthalene, and mixtures of the above, for examplecarbon monoxide and methane. Reference is made to FIG. 1B. Typicalresidence times are extended compared to the preferred furnace blackprocess, with residence times of the emulsion in the reactor typicallyin the order of 1 hours to 7 days, more preferably 8 hours to 3 days.The single-phase emulsion is as defined before, i.e. a water-in-oil(w/o) micro-emulsion or a bicontinuous micro-emulsion comprising metalcatalyst nanoparticles.

Related therewith, the invention also pertains to a process for thecontinuous production of the crystalline carbon structure networks in areactor 3 where a single-phase emulsion c according to the invention isinjected from the top of the reactor 3, said reactor preferably being athermal black reactor, preferably through spraying using an aerosolinlet 4, to obtain an aerosol, and wherein said networks e are formed atan increased temperature of at least 600° C., preferably 700-1200° C.and deposited at the bottom of the reactor, and wherein the increasedtemperature is obtained using combustion (heat source inside reactor,using air or oxygen), but wherein the emulsion is injected only underpyrolysis conditions. In a further embodiment, the continuous‘pyrolysis’ process encompassing an initial combustion step isconveniently operated with a carbon feed gas above its crackingtemperature such as methane, ethane, propane, butane, ethylene,acetylene and propylene, carbon monoxide, oxygenated hydrocarbons suchas methanol; aromatic hydrocarbons such as toluene, benzene andnaphthalene, and mixtures of the above, for example carbon monoxide andmethane. Reference is made to FIG. 1B. The residence time for theemulsion in the reactor is preferably in the range of 1 to 600 seconds,more preferably 5 to 60 seconds. The single-phase emulsion is as definedbefore, i.e. a water-in-oil (w/o) micro-emulsion or a bicontinuousmicro-emulsion comprising metal catalyst nanoparticles.

According to the above semi-batch and continuous processes of theinvention, crystalline carbon structure networks (i.e. networks ofcrystalline carbon structures) can be produced. In a related aspect, theinvention thus pertains to crystalline carbon structure networksobtained by or obtainable by the process of the invention. The term“carbon structures” are understood to comprise crystalline sp2-basedcarbon allotropes, i.e. substances in which a carbon atom is bonded toneighbouring three carbon atoms in a hexagonal pattern, includinggraphene, fullerene, carbon nanofibers and carbon nanotubes. The methodof the invention allows for the growth of crystalline carbon structurenetworks formed from carbon structures that are chemicallyinterconnected through a multitude of junctions, including Y- andH-junctions. In the context of the invention, a ‘network’ is preferablyunderstood to comprise at least 3, preferably at least 5, morepreferably at least 10, more preferably at least 100, more preferably atleast 500 chemically connected nodes.

The networks preferably have at least one, preferably at least two, morepreferably at least three, most preferably all of the followingproperties:

-   -   (i) Iodine Adsorption Number (IAN) of at least 250 mg/g, more        preferably at least 300 mg/g, preferably 300-1000 mg/g,        according to ASTM D1510;    -   (ii) Nitrogen Surface Area (N2SA) of at least 250 m2/g, more        preferably at least 300 m2/g, preferably 300-1000 m2/g,        according to ASTM D6556;    -   (iii) Statistical Thickness Surface Area (STSA) of at least 120        m2/g, more preferably at least 150 m2/g, preferably 150-1000        m2/g, according to ASTM D6556;    -   (iv) Oil Absorption Number (OAN) of at least 150 cc/100 g,        preferably 150-500 cc/100 g according to ASTM D2414,

wherein:

IAN=Iodine Adsorption Number: the number of grams of iodine adsorbed perkilogram of carbon black under specified conditions as defined in ASTMD1510;

N2SA=nitrogen surface area: the total surface area of carbon black thatis calculated from nitrogen adsorption data using the B.E.T. theory,according to ASTM D6556;

STSA=statistical thickness surface area: the external surface area ofcarbon black that is calculated from nitrogen adsorption data using thede Boer theory and a carbon black model, according to ASTM D6556; and

OAN=Oil Absorption Number: the number of cubic centimeters of dibutylphthalate (DBP) or paraffin oil absorbed by 100 g of carbon black underspecified conditions. The OAN value is proportional to the degree ofaggregation of structure level of the carbon black, determined accordingto ASTM D2414.

For each of IAN, N2SA (or NSA), STSA and OAN—all typical parameters forcharacterizing carbon black materials—the networks exhibit superiorproperties compared to traditional carbon black. The networks of theinvention are preferably characterized by at least one, preferably atleast two, more preferably all of (i), (ii) and (iii) since these aretypical ways of characterized the surface area properties of thematerials. In one embodiment, the networks exhibit at least one of (i),(ii) and (iii), and further comply with (iv).

These structures forming the network may be described as nanofibers,which are solid (i.e. non-hollow), preferably having an average diameteror thickness of 1-400 nm, more preferably between 5 and 350 nm, morepreferably up to 100 nm, in one embodiment 50-100 nm, compared to theaverage particle size of 8-500 nm for spherical carbon black particles.In one embodiment, the average fiber length (i.e. the average distancebetween two junctions) is preferably in the range of 100-10,000 nm, morepreferably 200-5000 nm, more preferably 500-5000 nm, as for instance canbe determined using SEM. Alternatively, the nanofibers or structures maypreferably be described in terms of an average aspect ratio of fiberlength-to-thickness of at least 2, preferably at least 3, morepreferably at least 4, most preferably at least 5; in sharp contrastwith the amorphous (physically associated) aggregates formed fromspherical particles obtained through conventional carbon blackmanufacturing. The aggregates of carbon structure networks according tothe invention are typically of the order of 0.1-100 microns, preferably1-50 microns, which is observed with Laser Diffraction and Dynamic LightScattering analysis.

The invention also pertains to a composite comprising carbon structurenetworks according to the invention, further comprising one or morepolymers, for instance for adding mechanical strength, electricalconductivity or thermal conductivity to said polymer-based composite.The networks may be added in any amount adapted to the desiredperformance, e.g. 1-70 wt %, more preferably 10-50 wt %, even morepreferably between 20-40 wt %, based on the total polymer weight in thecomposite. In one aspect, the composite shows a networkconcentration-dependent elasticity modulus (E-modulus, i.e. an increasewith increasing concentration of networks) for instance as measuredaccording to ISO 527.

EXAMPLES Example 1A. Preparation of Crystalline Carbon Structure Network

100 gallon of feedstock were prepared comprising of:

-   -   a) Carbon Black slurry oil (CBO or CBFS oil)    -   b) Water phase containing 3500 mM metal precursor salt (FeCl₃)    -   c) Water phase containing reducing agent (3650 mM citric acid)    -   d) Surfactant (TritonX; HLB 13.4).

The exact composition of the micro-emulsions (a+b+d) and (a+c+d) wasdetailed below:

Emulsion CEO Water/FeCl₃ Water/CA TritonX a + b + d 70% 10%  0% 20% a +c + d 70%  0% 10% 20%

Both micro-emulsions (a+b+d) and (a+c+d) were added together and asingle-phase micro-emulsion was obtained by stirring, and saidmicro-emulsion was stable for more than one hour, which was longer thanthe entire length of the experiment.

The networks thus obtained had the following characteristics:

IAN=382.5 mg/g, according to ASTM D1510

N2SA=350 m2/g (ASTM D6556)

STSA=160.6 m2/g (ASTM D6556)

OAN=170 cc/100 g (ASTM D2414).

Example 2. Carbon Black vs Network

The carbon networks according to example 1 were compared to conventionalcarbon black produced using (a). Standard grade carbon black typicallyhas a nitrogen surface area (NSA or N2SA) varying up to 150 m2/g(N100-grade rubber carbon black).

The morphology of the carbon networks was assessed by Scanning ElectronMicroscopy (SEM). It was found that the carbon network building blockswere chemically covalently linked solid carbon (nano)fibers with averagefibre diameters below 100 nm. On the other hand, the carbon blackbuilding blocks were nodules in which graphitic layers are organized ina spherical shape (8-300 nm diameter). SEM pictures of carbon black andcarbon networks building blocks are shown in FIGS. 2A and 2B,respectively. It was found that the carbon networks were organized inaggregate size 1-100 μm, while carbon blacks aggregates ranged typicallyfrom 85-500 nm.

Example 3: Effect of Metal Nanoparticles

The metal catalyst concentration had an effect on the final yields ofthe reactions: Three 20 g bicontinuous micro-emulsions were made fromisopropylpalmitate (35% wt), butanol (11.25% wt), Tween 80 (33.75% wt),water (20% wt). While the first batch was prepared without any metalnanoparticles, two batches involved 50 and 200 mM FeCl3 metalnanoparticles (based on citric acid and FeCl3 with ratio 10:1). Each ofthe emulsions were stable over the full length of the experiments. Theexperiment without metal nanoparticles was carried out at least 10times.

In each case, the emulsions were introduced in the middle of aquartz-tube of a thermal horizontal tube reactor. The reactor was heatedup to 750° C. (3 K/min) under 130 sccm of nitrogen flow and kept for 90min at the same temperature. In the first 60 min the nitrogen gas flowwas reduced to 100 sccm and ethylene gas was added at 100 sccm flow.During the last 30 minutes at 750° C. the ethylene was purged out fromnitrogen at 130 sccm for the last 30 min and the reactor was then cooleddown.

It is only with metal nanoparticles that carbon structure networks wereobtained. In none of the ten experiments without metal nanoparticlesnetworks were found. The test done in the presence of 200 mM FeCl3showed a yield increase of carbon structure networks, compared to theresults reported with 50 mM FeCl3.

A SEM picture of the networks obtained with a bicontinuousmicro-emulsion based on isopropylpalmitate (35% wt), butanol (11.25%wt), Tween 80 (33.75% wt) and water (20% wt), with 100 mM Fenanoparticles is shown in FIG. 3 .

Example 4: Graph E-Modulus in PA6

Carbon Network powder such as prepared according to the recipe ofexample 1 was compounded in different loadings (10, 20, 30, 40% wt) inPolyamide 6 (Akulon F223D), by means of a twin screw extruder (LID=38,D=25 mm) and compared to glass fiber (Chopvantage 3540) compounded at10, 20, 30% wt loadings under the same conditions. The E modulus wasmeasured according to ISO 527, dried as molded tensile bars. The resultsare plotted in FIG. 4 , and indicate a performance of carbon networks,which is comparable to that of glass fibers. Carbon black was found notto provide significant reinforcement in thermoplastic, at whateverconcentration.

Example 5: Graph Electrical Conductivity PA6 and PET

Volume resistivity was measured on different compounds prepared withcarbon network prepared using the recipe according to example 1, indifferent loadings in Polyamide 6 (Akulon F223D) and PET (Ramapet N1),by means of a twin-screw extruder (LID=38, D=25 mm). The results areplotted in FIG. 5 . The percolation curves show good dosage control inthe static dissipative range and that high conductive performances areachieved at high loadings. At the opposite, carbon black percolationthreshold for conductive applications was found at lower dosages, i.e.<20% wt, and dosage control in the static dissipative range wasunsatisfactory. Moreover, carbon networks compounds did not slough up to30% wt loading, whereas carbon black compounds are known to be sloughingalso at low filling degree.

Example 6: Mechanical Strength

Carbon nanofiber networks (low IAN, high crystallinity) obtained throughthe modified carbon black manufacturing process according to theinvention were found capable of enhancing the mechanical properties ofthermoplastic (and thermoset) polymer resins. Adding 10% by weight ofcarbon nanofiber networks to a polypropylene co-polymer resulted in anincrease in tensile strength (at break) of 15% and an elasticity modulusincrease of 16% compared to the neat polymer reference. ABrabender©Plasticorder© was used for mixing sufficient amount of carbonnanofiber networks and polypropylene at 210° C. and 80 rpm. Samples werecompression moulded and tested with an Instron 3366 10 kN tensile testerat 23° C., 50% RH.

Modulus (Young's Tensile Tensile Tensile Tensile Tensile stress atstrain at stress at strain at stress Yield Yield Break Break 10% 0.05% -(Zero (Zero (Automatic (Automatic CarbonX/ 0.25%) Slope) Slope) LoadDrop) Load Drop) PP (MPa) (MPa) (%) (MPa) (%) Average 1459.99 20.05 7.6819.76 9.80 Std dev  149.72  1.13 0.20  1.14 0.91  10.3%  5.6% 2.6%  5.8%9.3%

Modulus (Young's Tensile Tensile Tensile Tensile Tensile stress atstrain at stress at strain at stress Yield Yield Break Break 0.05% -(Zero (Zero (Automatic (Automatic PP 0.25%) Slope) Slope) Load Drop)Load Drop) reference (MPa) (MPa) (%) (MPa) (%) Average 1258.35 18.95 8.76 17.14 13.54 Std dev  141.14  1.17  0.89  1.37  4.30  11.2%  6.2%10.2%  8.0% 31.7%

Example 7: Production by Means of Plasma Reactor

Carbon nanofiber networks produced by means of using a plasma instead ofcombustion of a carbon gas. The plasma gas used was nitrogen (N2) at 60kW with an initial plasma flow rate of 12 Nm3/h. Argon flow rate was setat 0.6 Nm3/h. Feedstock (emulsion) flow rate was set at 2.5 kg/h.GC-measurements were done to monitor H2 and progress of the carbonconversion. Temperature at injection was set at 1400° C., approximatedresidence time was 4 seconds. The collected material has a density of0.13 g/cc and showed presence of carbon nanofiber networks observed viaSEM and TEM, see figures. The average fiber diameter was determined tobe 70 nm, while the length in-between was 5 to 10 times fiber diameter.

The invention claimed is:
 1. A crystalline carbon structure network,comprising chemically interconnected carbon nanofibers, wherein thecarbon nanofibers are chemically interconnected by chemical bondsthrough a multitude of junctions, including Y- and H-junctions,comprising at least 500 chemically connected nodes, wherein the carbonnanofibers have an average aspect ratio of fiber length-to-thickness ofat least 2, wherein the carbon nanofibers forming the network arenon-hollow and have an average diameter or thickness of 1-400 nm and/oran average length in the range of 100-10,000 nm, wherein the carbonstructure network is porous and forms aggregates with a size of 0.1-100microns.
 2. The network according to claim 1, obtainable by a processfor the production of crystalline carbon structure networks in a reactorwhich comprises a reaction zone and a termination zone, the processcomprising: (a) injecting a water-in-oil or bicontinuous micro-emulsioncomprising carbon components in an oil phase, metal catalystnanoparticles having a size between 1 and 100 nm, and water into thereaction zone at a temperature of above 600° C., to produce crystallinecarbon structure networks, (b) transferring the networks to thetermination zone, and (c) spraying water into the termination zone,thereby quenching or stopping the formation of crystalline carbonstructure networks.
 3. The network according to claim 2, wherein thereactor is a furnace carbon black reactor comprising, along the axis ofthe reactor, a combustion zone, a reaction zone and a termination zone,and wherein the process comprises producing a stream of hot waste gas inthe combustion zone by burning a fuel in an oxygen-containing gas andpassing the waste gas from the combustion zone into the reaction zone,spraying the water-in-oil or bicontinuous micro-emulsion in the reactionzone containing the hot waste gas, carbonizing the emulsion at atemperature of above 600° C., and quenching or stopping the reaction inthe termination zone by spraying in water, to yield crystalline carbonstructure networks.
 4. The network according to claim 3, wherein thetemperature in the reaction zone is above 1000° C.
 5. The networkaccording to claim 1, wherein the carbon nanofibers have an averageaspect ratio of fiber length-to-thickness of at least
 5. 6. A compositecomprising a carbon structure network according to claim 1, furthercomprising one or more polymers, wherein the network is present in anamount of 1-70 wt %, based on the total polymer weight in the composite,suited for adding mechanical strength, electrical conductivity orthermal conductivity to the composite.
 7. The composite according toclaim 6, having an E modulus increasing with network concentration asmeasured according to ISO
 527. 8. The network according to claim 1,wherein the carbon nanofibers forming the network have an averagediameter or thickness of 5-400 nm.